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GEsControl Level Evaluation

Process introduction

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What CLE is ?workout method

resolve quality issues / implement proactive quality process mapping focused on describing critical to quality parameters for

each process step (output and input CTQs).

the way to identify weak points of process which have to be improved toassure part/product quality

focused team of experts

identify process steps / inputs / outputs

develop and execute an action plan to improve

Six Sigma approach systematically reduce the Cost of Quality

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To minimalize internal scrap cost by implementing mistake-proofsolutions at the very begining of process. IndicatorsProduct criticality, Sourcing and Product Management

startegy. Main focus on residential & protective product vendors.

Risk factors & actual quality performance Resolve systemic supplier, customer and sites quality issues with

high quality costs.

Find-out process control gaps in order to have process morefoolproof.

What is the benefit?

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Philosophy why CLE?Cost Of Quality vs. where/when the defect is likely to be detected.

The most effective and less costly is

to detect and solve isses at design

stage.

Some issues detected duringmanufacturing can be solved or the

risk can minimalized by implementingchange in design.

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Program principles

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L1 : Poka-yoke you can not make a mistakeNo bad products, no scrap/warranty costs

L2: Early warning alarms before you make a mistakeYou have the chance to prevent bad products

L3: Operator dependency it is documented what iswrong, but you have to check. Mistakes can (andwill) happen

L4: Unknown level you dont know, you dont controlDisasters (can) happen...

Control Level - definitionWhen all CTQs are identified its time to determineappropriate Control Level for each of them.

Control Levels:

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Control Level outcome & expectation

All parameters clasified as CTQ should have assignedappropirate Control Level (CL).

There are 4 possible CLs: L1 (foolproof) , L2, L3 and L4 (nocontrol)

Program target: L1L2% equal or greater than 80%

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How to control a process?

Example: making tea at homewho is your customer? what does he/she wants?

what are the critical things to your success?

what are your process steps?

outputs?

inputs?

how can you control?

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Control level example

Control Level ExampleL1 Poka-yoke Closed heating system l ike in an espresso machine):

- it doesnt let out water below or above boiling point- when you press the button you always receive water at 100C- you can not make a mistake here

L2 EarlyWarning Electric water kettle:- red light means water is heating up- loud click & red light turns off means water reached 100C- early warning system: decision about the output (100C) is independent

from you and it has a clear signal but if you pour out water while the lightis on, you will make a mistake (making a cold tea)

L3 OperatorDependent

Heating water in a cooking pot:- you have received a training: water is boiling when bubbles appear- you must constantly check, and make a decision if small bubbles are

good enough or wait a bit more for large bubbles to appear

L4 Unknown You dont know... that you need water at 100C / you think any warm water will do

Tea making: the water is boiling- output (water heating process step): water is at 100C

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The CLE workout

identify process steps / inputs / outputs

classifying workstations

setting up priorities

develop and execute an action plan to improve

Define Measure Analyse Improve ControlDP0: Initiate need

for CLE

DP1: Data

preparation

DP2: the CLE

workout (this step)

DP3: project

execution, goal

attinment

DP4: sustained

quality levels

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Prioritize

DP

DP1

DP2

DP3

DP4

ANALYSE:o Supplier Workouto Detailed Action Plano Resource Commitment

SELECT SUPPLIERS for SWAT event

DEFINE:o Prepare audits plan, assignSQE.o Choose exact products to beevaluated

MEASURE:Data Preparation Quick Fixes/Final Firewalls CTQ requirements Action Log - Prioritized Scorecard Quality Metrics Goals/Benefits/Schedule Required Funds

IMPROVE:o Project Executiono Monthly Pulsingo Goal Attainmento Consultation sessionsCONTROL: Sustained Quality Levels

Validate Results with ScorecardLong Term Control Plan

Validate Long Term Control

CLE Process Steps

On site

1 DAY

2 DAYSremotely

At supplier site

Supplier involvement

Gtem

S

e

Gtem

S

e

Remotely

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